Another Cordite Is Born ...

[fatbloke]

Paul, you seem to have the kit car "Silence of the Lambs" syndrome - "He puts the filler on it's skin and then he sands it off again". ;-)

I thought I'd slapped a lot of filler on mine but you've taken it to another level. Looks great though.

[Paul L]

Fatbloke - Well, I am certainly not doing extra filler work for pleasure.

Thankfully the fibreglass work underneath provides all the strength, with the filler making it smoother (ish).

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I'm knackered…
Made great progress in the garden, but it was seriously back breaking work.

My wife & eldest daughter had pressure washed the patio & garden path, so I had some pointing to do.



Managed to find my cement working set up at the back of the shed.



I patched all the missing pointing, although at some point some slabs need to be lifted and relaid.



It was so hot today, that it didn't take long for that to set and get the table back in position.



Next it was time to tackle this corner…



And in best Blue Peter fashion, here is something I painted earlier.



A bit like the front arches, sometimes it gets worse…



Before it gets better...



Although, also just like the arches, there is still a bit of work left to do.



Hopefully, I can get the last few garden jobs done before next weekend.

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Roadster's Visit:
Great to meet Roadster in person and chat about our builds & the forum.

Although in true gremlin style, the ignition fault was back and I couldn't start the engine.

So I will have to spend some time tracing this problem & fixing it once & for all.

I think he will be able to confirm that my over-engineering approach has resulted in a very "solid" car.

But the really good thing was getting an independent view on the overall build.

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Another photo of the original Ribble Cordite Demonstrator caught my eye this morning.



As this is another area where my scuttle design is a bit different to the original.



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We made the most of the great weather to have a family BBQ this evening and I am now going to put my feet up.

The physical effort I've put into both the car and garden over the last few weeks has taken its toll.

So I'm off to have a cold beer and a rest.

Until next time, take care, Paul.

[Roadster]

Good to meet you too Paul
After so many years supporting each other on here

No 2 Sammios are ever the same but Paul's approach to every obstacle has resulted in a very solid body/chassis unit.

I have seen a number of Sammios in the flesh, being about when Gary first started. This one is very sleek and the stance is low.
No vents in the bonnet and the combination of lower front end position and the bigger scuttle area. The rear is much lower and wider than the others.

There is not much Cordite that hasn't been modified so the its almost a completely new model.

It will be interesting to see it with the other finished examples

[Paul L]

Roadster - Thanks again for making the effort to visit and say hello, I'm really glad you liked it.

Originally Posted by Roadster

…It will be interesting to see it with the other finished examples...

One day I will appear as d'Artagnan next to Norfolk's Three Musketeers, one day.

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Monday - After work I had no energy to do any work on the car, or in the garden, so I just rested.

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Tuesday - Vistor #2:
A bit like buses, you wait 4 years for one forum visitor, then 2 turn up in 3 days.

Jokes aside, Jones was today's guest of honour and it was great to meet him too.

Had a good chat and thankfully the engine started today, after I randomly wiggled some wires.

It seems that "solid" is a recurring theme for anyone who gives the car a bit of a shove.

I look forward to the day when myself and Jones both have MOTs under our belts.

But I'll leave you with a rough idea of where the bonnet strap will end up.



Until next time, take care, Paul.

[Paul L]

Close, but no cigar…
I've got a few days off work now, but spent the morning in the garden, which is now done.
( Well, at least it is done enough for our guests arriving on Saturday. )

But the really good news is that I'd earned enough brownie points to switch to car work.

So gathered what I needed from the Summer House, but only got as far as the porch before it started to rain.



Switched to some internal domestic chores instead until the sun was back out and the clouds were gone.

Just before I went out the front, I remembered there was bonus brownie points available if I painted the patio door threshold.
( Which my wife has been sanding, filling and priming over the last few days. )



Unfortunately, just as I put the lid on the paint tin, I felt a drop of rain, looked up and saw this bearing down overhead.



By the time I got everything inside, all hell was breaking loose outside.
( Note the off cuts of fibreglass under the car I was planning to cut up for the bonnet. )



It looked even worse out the back.



Still, at least you can get a good view of all the edging work I've been doing.

Plus, if I'd actually removed the covers from the car to start working on it, it would have quickly filled with water.

As it is, it is still absolutely lashing down down.

So I'll do some more stuff indoors for the rest of today and hopefully get a long session on the car tomorrow.

Until then, take care, Paul.

[Paul L]

Big Thursday - Part 1:
Finally, here is a post that actually includes some work on the car…

Once again there was no problem with the ignition as I started the engine and went for a spin.
( OK, I know it is only a few feet forwards and backwards. )

But here are a few seconds of "Driver's Eye" view:
( Although seats will be a little higher when they are bolted into position. )

https://youtu.be/4CaUHkr_fxQ

Note:
The loud rattling sound is the bonnet due to the fact the rubber seal for the scuttle is not fitted.

Anyway, that will be the last drive for a short while, as I want to finish off the inside of the passenger side.

So I jacked up the car, left it on blocks of wood & removed the wheel.





I have one last bit of the original arch left to play with.



And this is the gap I need to fill in.





Made an oversize template for the bottom edge.



Then trimmed the small return piece for a best fit and adjusted the cardboard to match.



Ground down the protruding edge of the body shell extension until it was level with the horizontal panel.
( Edge is on the right side of the photo. )





With the final bonnet piece cut out of fibreglass, I marked up & trimmed the bottom corner.





Hopefully the rounded edge will look nicer when the body shell is built up to match.

End of Part 1…

[Paul L]

Big Thursday - Part 2:
Then the two pieces were fixed into position and to each other.





Given all the angles involved, I will be grinding down the outside of the corners to get a nice "flow" across the join.

Unfortunately, there is still a little bit of flex in the bottom edge of the bonnet, which makes it harder to line things up.

So I mixed up a small quantity of bonding paste…



To fix a length of rope along the inside edge of the bonnet's curve.
( I will then cover the rope with some fibreglass matting. )



I also fixed another length of rope along the inside edge of the body shell extension.



Again, hopefully, this should reduce any flex in this area too.

The first round of fibreglassing covered the following areas:

The top edge of the horizontal panel.



The underside of the same panel along the joins.



Starting to build up the "curve" on the body shell to match the bonnet.



The corner of the scuttle.



And the inside of the pieces added to the bottom edge of the bonnet.



In the winter, the sun rarely reaches the driveway, but today I'm working in a sun trap, which was HOT!

So the 'pot life' of the resin is short and this creates a mad rush to get everything in place.

End of Part 2…

[Paul L]

Big Thursday - Part 3:
Still, at least I didn't have to wait too long before I could remove the brackets from the bonnet.



Recover the outside with parcel tape.



I ground down any stray bits of matting around the fixing holes, but needed some shade before the next layer of matting went on.





This round of matting went on the bottom edge of the bonnet.



And the "curve".



Note:
I should point out that in between all the car work listed above, I was still working my way through a long list of domestic chores too.

Once that was set solid, I trimmed off any stray matting, before grinding out the "wounds" on the Sunny Side of the bonnet edge.
( I also counter sunk the fixing screw holes. )



Then I mixed up some fibreglass filler to fill in the holes.



And cover parts of the body shell side extension.



I wasted a chunk of filler and the stuff I applied is very messy as the heat meant it set before I could finish applying it.

So I had to mix up a small second batch to finish the job.

End of Part 3…

[Paul L]

Big Thursday - Part 4:

Eventually, that was set enough to be sanded back down again.







Not a great photo, but the body shell "corner" curve is coming along too.



Actually, it is much easier to see in this photo.



Now given all the time & effort it has taken to reach this stage, I am very happy with the result.

Believe it, or not, but I still have some domestic chores to do, so I'd better go.

Take care, Paul.

[Paul L]

Evolution, not Revolution:
When talking to Jones the other day, I mentioned that my build had followed a 'making it up as I go along' development path.

And that I usually have so many jobs left to do, that I don't often stop to really appreciate the amount of work I've already done.

Well, by the time I posted the last photo in yesterday's update, I was running on empty and still had stuff to do.

However, the more I look at that last photo, the more my spirits are lifted, as the end result will definitely be worth all the effort.

But in terms of "making it up as I go along", here is how my plans for the front arch "developed":

Plan A
- My Spitfire bulkhead is much higher than the set up used by Mac & Swifty.
- So if I ran a straight line from the horizontal "shelf" on my bulkhead, it would miss the wheel arch completely.



Plan B
- Still using the Spitfire bulkhead's horizontal line, but the "cut away" line was now matching the angle of the scuttle.



Plan C
- Started to form when this photo of Micky1Mo's "new" Sammio Spyder appeared.



- Which I tried to replicate by drawing on a printed photo of my car (Blue Peter remains a big influence on my build ).
- Although Fwingo subsequently posted a great photoshopped version of how it might look that was miles better.



The key to making this design work was building a "two tier" bulkhead.
( I really like the way this has turned out in practise. )



Yesterday's "reality"



What is really striking (to me at least), is how much 'deeper' the body shell extension is compared to how thin the original bonnet end was.
( This is partly due to the differences between the passenger and driver's sides, as the bottom of the bonnet is actually deeper on the driver's side. )



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Finally, you may have seen that Adam is selling his unfinished Cordite/Navigator.

These are the photos of his original (read not butchered) body shell and bonnet.





They really bring home the sheer volume of changes I've made to the kit I bought.

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Right, I have a busy day ahead, which will involve more juggling of domestic and car chores.

So hopefully there will be another update car later on today.

Until then, take care, Paul.

[jones]

So as Paul alluded to I was very lucky to be able to pop in for a cuppa and a freshly opened pack of Hob Nobs - chocolate no less!

The one thing I will say is that the pictures do not give justice to actually how good this build really is.

• The reuse of the spitfire bulkhead is once it's all painted going to give a look of a production racer
• that rear end is slick - looks low and wide with the cuts into the hump for the boot working visually really well
• Progress on the wheel arches an absolute (ahem) Triumph!
• the engine sounds great, and the smile he wore was like that kid at Christmas who got the Meccano set
• SOLID! that car has no flex - the panels are solid, I did say to Paul that he should get it weighed at the local scrap merchant when complete as I feel it would be a close thing between donor and the finished Swordfish 1500

All in all it was a good visit - Paul is exactly as he comes across on this forum, a genuine nice guy whom I admire for the tenacity of completing the build on that 1:3 gradient driveway open to the elements. The final build I have no doubt will be a great end result.

Thanks again Paul for taking the time to show the car and have a general chat.

[Paul L]

Jones - Will you behave? You are making me blush.

Jokes aside, it was great to meet you and I'm glad you liked my car.

I will definitely drive it over to your neck of the woods when I am on the road.

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Frantic Friday - Part 1:
Today has been very hectic to say the least, but I did managed to get some more car work done.
( I'll spare you the details of all the domestic chores that were done in between. )

Round #1
Started by added some fibreglass matting over the rope I bonded to the bonnet yesterday.



I also built up the inside of this corner, as I need to grind down the other side to line things up.



I also healed the wounds on the sunny side of the bonnet.



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Round #2
Added the next layer over the bonnet rope.



Added the first layers over the rope running along the bottom of the body shell extension.



Now this is very hard to reach (even with the car jacked up) and working upside down is a pain.

However, you definitely need some eye protection to avoid resin drops!



End of Part 1…

[Paul L]

Frantic Friday - Part 2:

Round #3
After some sanding down and tidying up of any stray bits of fibreglass matting I was left with this.



Fixed up some fibreglass filler to start the smoothing out process.



Also added some "normal" filler to the side extension.



Then I put the wheel back on.



I know I still have work to do in this area, but I need to make sure there was nothing car related in the house.

Which is why I then lowered the car back to the ground.



As this allowed me to move the jack & other tools back to the Summer House.



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Round #4
After roughly sanding all the filler down, I wanted to reverse the car out of the way so I could clean the drive.

It started up no problem, but then spluttered and died and would not re-start.

Thankfully, checking the glass fuel filter confirmed there was no petrol in it and then it dawned on me…

The garage has drained the tank after finding old petrol in the carbs & hadn't put much fresh petrol back in.

So after topping up the tank with some petrol it started again and confirmed the fuel gauge is actually working.
( It was just showing "empty" before. )



Note:
The gauge reads low due to the angle of my driveway.

So with the car out of the way, I could clean up the mess.





And while the car was away from the wall, I took a couple of photos of my progress.

Now remember, the car is still tilted and the rubber seal for the bonnet isn't fitted, but it is shaping up.



Overall, I'm a very happy bunny.



So that is it for car work until at least Monday.



I've just got one last chore to do, but there is a cold beer waiting for me in the fridge.

So until next time, take care, Paul.

[Roadster]

Looking Good Paul
Now you have one side in the bag the other side has less head scratching

[Paul L]

Roadster - Cheers.

I am confident (for a change) that the driver's side will be easier to do for a number of reasons:
- Obviously, I've just done the passenger's side.
- The gaps are not as big on the driver's side.
- I plan to steal, sorry, borrow, an idea I saw on Jaguartvr's build "next door"...

To date, I've used recycled bits of fibreglass and metal to hold all the pieces together like this.



Whereas, Jag's use of "builders band" would give me much more flexibility.
( In terms of lining up the screw holes and getting the right curve in the bracket. )



So I plan to buy some strips of this stuff and use them to bolt the whole driver's arch jigsaw puzzle together in one go.

Hopefully, this should reduce the time I spend building up the passenger side, one small section at a time.

Well, that is today's theory anyway.

Right, I've got to get ready for a trip to the airport, so I'd better go.

Take care, Paul.

[DaveP]

Paul as ever a great thread with so much detail. I feel almost like we live next door to you with the level of detail.

Also you should be very proud of not only the vision of what you wanted to achieve but also in getting there. Your patience is admirable.

Keep up the good work

Dave

[Roadster]

Originally Posted by DaveP

Paul as ever a great thread with so much detail. I feel almost like we live next door to you with the level of detail.

Also you should be very proud of not only the vision of what you wanted to achieve but also in getting there. Your patience is admirable.

Keep up the good work

Dave

Wait till he gets it in paint - he will be like a dog with two tails.

The end is in sight now, with the hours that have gone into this build I hope Paul drives it at every opportunity.
After I finished the roadster, I didn't drive it as much as I should. Sure I took it to a show or 2 but I should have gone for a blast round the lanes at any excuse.

Sunday afternoon trips ending in a pub garden were always good.

[Paul L]

Shhh…



Everyone else in the house is still asleep, so I am typing this post very quietly.

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DaveP - Thanks, after such a long & frustrating build, it is great to finally be heading towards the finish line.

Although, I can't quite believe what a transformation the body shell extension work makes to the overall look.
( As modifying the front arches has been on my "To Do" list for years. )

Driver's Side - To Be Done:



Passenger Side - Almost Done:



I'm really looking forward to reaching the point where I can get some etch primer on this side.

I think Christinedmc was the first person I remember doing this mod on Spyder #47.
( Although the G-46 incorporated this approach in it's original design. )

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Roadster: - Well, I certainly plan to rack up some miles to "pressure test" the body work.

As I'd much rather discover any issues with cracking, etc. before I even think about paint.

However, I expect the day when the paint is done and the final sticker is applied to be worthy of a major celebration.

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Take care, Paul.

[oxford1360]

Looking great, Paul.

It is now 48 hours since your last post. I am on the verge of submitting a Missing Persons report.

[Paul L]

Oxford: - Thanks, I'm lovin' the way the final shape is turning out.

And there is no need to report me missing just yet.
( I was just about to paste the post below, when I noticed your reply. )

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Frustrating Times:
My wife's brother and sister-in-law enjoyed their visit over the weekend, so all the preparation effort was worth while.

But by the time I got back back from the airport on Monday I was so tired I ended up sleeping for 3 hours in the afternoon!

My work project has been temporarily put on hold, so I am likely to be off work for all of this week.

Which would have been a great chance to make some significant progress on the car, if the weather wasn't so !

I did make an attempt at car work this morning...

I gave the body shell extension a final sanding along the "middle".
( Note: I still need to do some more filler work at the top & bottom. )



I cleaned the area and was actually shaking a can of etch primer when the rain started.



Thankfully, I had only peeled the covers off from the front of the car, so it was all quickly covered back up.

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I finally got some etch primer on during the next decent break in the rain.



Although it would probably have been a better idea to wait until all the filler work was done.

Then I wrapped up the headlight & indicator to protect them from all the filler dust.



But as soon as I had cleaned the panels and got my tubs of filler out, the rain returned.



So I quicky put everything away and got the covers back on.

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"You gotta know when to fold 'em."
It is hopeless trying to get anything constructive done at times like this.

So I guess I will just have to wait and get on with other stuff instead.

Until next time, take care, Paul.